Now that the warm weather has returned I have noticed the same odor problem with my 04 DC AC system. If I run the AC untill I shut the car off I see a large amount of condensation dripping under the truck. I am assuming that most but not all of the condesation is being routed away from the heat exchanger and the water that can't get away begins to promote mold growth and smell the next time I turn the AC on. If I turn the AC off 5 minutes before I shut down the truck and run the fan only I don't have the problem next time I run the AC but I don't feel like I should have to do this.
Has anyone come up with a mechanical fix for this? I am not really interested in spraying some type of chemical cleaner in there because I'm sure the problem will return. Has anyone taken apart the condensation catch tray? How do you get to it on the DC? Is there a design flaw that causes it to hold water?
I run my ac on the recycle mode and don't have the problem. From what I understand, it can only be properly cleaned with the chemical spray. I turn off my ac and let the fan run with the windows down for about a block before shutting down. Then when I run the ac I use the fresh ac mode for a block with windows down before using recycle. If you're still under warranty have madera toyota check if there's a problem. You also might want to try spaying lysol into the exterior intake vents. Try it using fresh ac mode then switch to recycle. This is only a temp fix, you will have to do this about once a week. I also used some ac spray cleaner at kragen that is used on interior and exterior vent. I used to have the mold problem in my old jeep grand junker. It is a nasty and annoying problem, it does't seem like this should occur in a truck that's only 2 yrs. old
Some people live an entire lifetime and wonder if they have ever made a difference in the world, but the Marines don’t have that problem. —President Ronald Reagan
You both are correct. You need to run it about a block on fresh without the ac on before you shut it down. The spray is the only method I have heard of and what we used at the dealership I worked at. I use Lysol.
__________________ '05 Tundra DC TRD 2 WHL: The TOW truck, Spectra Mica Blue, with Kenwood H/U, Kenwood Amp and crossover. Infinity 6010cs, 10" Rockford SUB, 6 disc CD Changer mounted in Center console, SWI-X to retain steering wheel controls, 7" TV with DVD. Tinted Windows, Three chamber Flowmaster, Painted front chrome strip
1994 Toy: The TOY Standard cab, Long travel front pulling13" w/Double fox w/Res, Deaver rear at 18" w/Single 2.5 18" fox w/Res., full glass, Bumper to Bumper cage, Gusseted frame, PRP seats, Crow harnesses, Custom steering(All Heims & Chromoly), Grant steering wheel, Smoothest ride around. OH by the way only 70,000 miles.
The Lysol work, but seems to be short term, I've tried it as Pat Goss directed.
Run your truck with the heat and fan on high, spay a can of Lysol in the air intake, dont forget to have the doors open.
Also, running the heat and fan on high in a used care can clue you in if its had water/flood damage. The heat and fan will oncover what someone maybe hiding.
based on the amount of out door debris caught in our corolla's a/c filter, and knowing the tundra doesn't have a fiilter, i think it's pretty likely we all have some leaves, pollen, small branches, bugs, etc in our a/c and heater core coils. something like that could easily plug up the small drain holes and cause water to be trapped in there.
AC Smell is Back!
'05 Tundra DC TRD 2 WHL: The TOW truck, Spectra Mica Blue, with Kenwood H/U, Kenwood Amp and crossover. Infinity 6010cs, 10" Rockford SUB, 6 disc CD Changer mounted in Center console, SWI-X to retain steering wheel controls, 7" TV with DVD. Tinted Windows, Three chamber Flowmaster, Painted front chrome strip 
1994 Toy: 
Linear Mode
